Method for producing thin wall, indented bottom thermoplastic containers



Feb. 8, 1966 B. EDWARDS 3,234,310

METHOD FOR PRODUCING THIN WALL, INDENTED BOTTOM THERMOPLASTIC CONTAINERS Original Filed Sept. 17, 1959 8 Sheets-Sheet l INVENTOR.

Brycmz Edwards BY Feb. 8, 1966 B. EDWARDS 3,234,310

METHOD FOR PRODUCING THIN WALL, INDENTED BOTTOM THERMOPLASTIC CONTAINERS Original Filed Sept. 17, 1959 8 Sheets-Sheet 2 I N VEN TOR.

Bryan? Edwa rcis BY 0 3 I 3 m 4 h 3 6 n/w w 3 e e h D S m 8 m S m I N n U T m. N R T we Feb. 8, 1966 B. ED METHOD FOR PRODUCIN BOTTOM THERMOPLAS Original Filed Sept. 17, 1959 INVENTOR. Bryanifawards BY IHIWWIIHIHI Lil/1|? 8 E 3 mi 3 E Q a" Em i F E E E E Q N W: aw E M Ful-llllnl -l .IIIHIIHIIPIMWIMI Feb. 8, 1966 B. EDWARDS 3,234,310

METHQD FOR PRODUCING THIN WALL, INDENTED BOTTOM THERMOPLASTIC CONTAINERS Original Filed Sept. 17, 1959 8 Sheets-Sheet 4 v %,83 LN 582 IN VEN TOR.

Brycmi Edwards BY (Ma w 01?.

Feb. 8, 1966 B. EDWARDS METHOD FOR PRODUCING THIN WALL, INDENTED BOTTOM THERMOPLASTIC CONTAINERS Original Filed Sept. 17, 1959 las Fig.8

"\"wam my Feb. 8, 1966 B. EDWARDS 3,234,310 METHOD FOR PRODUCING THIN WALL, INDENTED BOTTOM THERMOPLASTIC CONTAINERS Griginal Filed Sept. 17, 1959 8 Sheets-Sheet 6 INVENTOR. Bryan? Edwards BY Feb. 8, 1966 B. EDWARDS 3,234,310

METHOD FOR PRODUCING THIN WALL, INDENTED BOTTOM THERMOPLASTIC CONTAINERS Original Filed Sept. 17, 1959 8 Sheets-Sheet 7 IN V EN TOR.

Bryani Edwards {Jaw W @629.

Feb. 8, 1966 B. EDWARDS 3,234,310

METHOD FOR PRODUCING THIN WALL, INDENTED BOTTOM THERMOPLASTIC CONTAINERS Original Filed Sept. 17, 1959 8 Sheets-Sheet 8 (I63 Am 1 I o O f i i 84" 1 36" h I F \(QVA;IIIDAFAVA I A m (23 226 I H In F1 15 1:1 1 1 .16 u flu rae INVENTOR. 52 254 Brgani Edwards 1 13.17 BY Unitcd States Parent cc 3,234,310 METHQD FGR PRQDUCENG THEN WALL, INDENTED BUTTUM THERMQPLASTEC CONTAENERS Bryant Edwards, Gal: Parlr, lll., assignor to Illinois Tool Works, Inc, Chicago, 112., a corporation of Illinois Original app ication Sept. 17, 1959, Ser. No. 849,604, now Patent No. 3,059,816, dated Oct. 23, 1962. Divided and this application Feb. 23, 1962, Ser. No. 175,224 7 Claims. (Cl. 264-93) This application constitutes a division of my co-pending application, Serial No. 840,604 filed September 17, 1959, now Patent No. 3,059,810.

This invention relates in general to containers formed of plastic material and, more particularly, relates to thin wall plastic containers which are formed with a false bottom, that is to say, a bottom which is concaved axially upwardly a predetermined distance above the outer and visible side walls of a container.

There has existed a long-felt need for a thin walled plastic container having a false bottom. An advantage that accrues to a false bottom container, over a container having the bottom wall at the base of the side walls, relates to the stacking of a plurality of empty containers in telescoped relation in a manner to quickly facilitate easy removal thereof. The false bottoms, it will be apparent on reflection, space the individual containers one from the other in a manner not requiring auxiliary lugs or stacking rings which are often necessary on non-false bottom containers. The stacking feature is very important in containers to be associated with automatic equipment.

When thin wall plastic flush bottom containers are utilized with hot beverages, the heat from the beverage may damage surfaces upon which a flush bottom container is deposited. With a false bottom container, this situation is alleviated. In certain automatic vending machines dispensing hot beverages into containers, a false bottom container is found to be very useful in manual transportation of a filled container from the vending machine to the place of consumption. The construc tion of the false bottom container to be described in detail hereinafter is particularly advantageous in this regard due to the double thickness of the skirt portion defining the so-called false bottom.

A particularly import-ant area of application of thin wall plastic containers of the false bottom variety is in the so-called throw-away or disposable container field. The particular problems involved relate to efiicient manufacture of a container so as to be competitive with conventional containers while retaining the advantages that accrue to plastic materials. The articles to be later described in detail, that form a part of this invention, have the requisite strength, are easily formed in large numbers by mass manufacturing techniques, are aesthetically pleasing, and are otherwise well adapted for their intended purposes.

It has been found that one efficient manner of produc ing containers and the like involves their being molded from sheet thermoplastic material. This method contemplates warming the material, mechanically drawing it to a partially completed form, blowing air under pressure thereinto to form the material into the configuration of a cavity or mold and then immediately, while the formed plastic material is still in a heated pliable and plastic form, causing relative movement of certain parts of the plastic material in turn to cause a portion of the previously formed plastic material to adhere back upon itself to provide a novel false bottom container of superior characteristics. This invention relates to the novel container, improvements in a machine for producing sup an Patented: 8, 1966:

2, pc-rior false bottom container, and the "novel methods of producing said container. 1 l

In my co-pending application entitled Container Moldmg Machine having Serial No. 763,668 filed on September 26, 1958, now abandoned, and the continuation thereof filed on December 7, 1962 with Serial No. 243,166 and copending herewith, I disclosed a machine wherein the plastic sheet is prestretched biaxially to accomplish molecular orientation in the sheet material, clamping or support means for holding a given area of the plastic material before and during the mechanical drawing of the material, and before any portion of the sheet material engages a complementary mold or die, improved mandrels or male die members which have controlled frictional and heat transfer characteristics, improved means for sealing off and shearing selected area of plastic sheet material all of which formed containers of improved uniform characteristics and of a superior finish.

I have elected to show a modification of the aboveidentified machine which will readily produce my novel false bottom containers. While I have elected to show a machine of the general characteristics of the aforementioned copending application, it will become obvious throughout the specification that there are other and dif ferent machines adaptable to producing my novel containers which may be used with equal facility as the instantly disclosed machine.

It is an object of this invention to provide a thin wall container with a novel false bottom feature having the characteristic of an annular depending side wall skirt portion, the cross-sectional thickness of the said depend- 1ng skirt portion being substantially double the wall thickness of the remainder of the container.

It is still another object of this invention to disclose a method of taking a preformed container, and while it is still in a plastic stage and by means hereinafter disclosed, causing portions of the preformed container to be moved and thereafter to adhere to the adjoining container side wall thereby to provide the novel false bottom plastic container.

It is further, an object of this invention to provide an unproved machine for practicing the methods by which the novel container may be formed.

The novel features that are characteristic to the inventron are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and its method of operation, together with additional obects and advantages thereof, will best be understood by the following description of the specific embodiments wllienhread in connection with accompanying drawings in w 1c FIG. 1 is a side view of a machine constructed in accordance with the principles of this invention for making thin wall plastic containers having a false bottom;

FIG. 2 is a vertical cross-sectional view through the machine as taken along line 2-2 in FIG. 1;

FIG. 3 is a horizontal cross-sectional view through the machine as taken along line 3-3 of FIG. 1;

FIG. 4 is a view somewhat similar to FIG. 3 and showing a modification of the machine where the plastic sheet stock or web is stretched biaxially;

FIG. 5 is an enlarged fragmentary vertical sectional view through the mold cavity showing the male member or mandrel before initial drawing of the sheet material as taken along line 5-5 of FIG. 2;

FIG. 6 is a view similar to FIG. 5 showing the relative relationship of the parts following the mechanical draw-- ing of the web;

FIG. 7 is a fragmentary view similar to FIG. 6 showing a subsequent step in the operation;

FIGS. 8 through 10 are views similar to FIG. 7 show- 3 ing the next succeeding steps in the operation of the device;

FIG. 11 is an enlarged fragmentary sectional view of the lower right-hand corner of FIG. 8 of the drawings;

FIG. 12 is an enlarged fragmentary sectional view of the lower right-hand corner of FIG. of the drawings;

FIG. 13 is a fragmentary sectional view showing the relationship of a plurality of false bottom containers when they are placed in stacked relation;

FIG. 14 is a semidiagrammatic isometric perspective view, with portions being broken away, illustrating the relative movement of the various parts of the machine to produce the false bottom container;

FIG. 14a is a semidiagrammatic view of an alternate method of accomplishing movement of the knockout plug relative to the female mold member during and after the formation of the false bottom container.

.FIGS. 15 through 17 are views similar to FIGS. 7 through 9 showing an alternative method of making a false bottom container.

In the art of forming containers and the like from plastic materials of the thermoplastic variety, two major methods have been used heretofore, namely, that of injection molding and the second type which may be designated as pressure molding. In the latter method a pressure differential is created across a web or membrane of thermoplastic material to cause it to move into engagement with a mold member. Methods to be discussed hereinafter in greater detail generally relate to the second type of molding process, but the preferred method employs a'combination of use of pressure differentials along with a mechanical drawing of the sheet material to achieve the desired results.

While containers may be formed by a blow molding or vacuum molding process without any mechanical engagement of the web of heated thermoplastic material to form the container, I have found that more uniform results are obtained by mechanically drawing the heated thermoplastic material with a mandrel to cause the major deformation of the web or sheet stock, then clampingly engaging the drawn material around the periphery of a chilled mold member, and then introducing a fluid pressure differential (preferably air pressure differential to the drawn Web or film of material to cause it to operate from the mandrel and quickly engage the cooled mold cavity. I have found that if the bottom or end surface of the mold cavity is not chilled as is the rest of the cavity,

(and in some cases even is heated), then the complementary portion of the container. which initially engages the bottom surface of the mold cavity may be displaced from this preformed stage and literally may be lifted or moved towards the open end of the container to a position it had assumed when the pressure differential was first created. When moving the bottom portion to its second position as just discussed, it is important to avoid stretching the material at the juncture of the side walls and bottom of the container as this would weaken the area substantially. I have found that by using the apparatus and methods which I am hereby disclosing the bottom-most portion of the side walls of the container adjacent the bottom of the container in the preformed stage may be folded back upon themselves, which folding affords several important results.

One of these results is to assure that there is no interruption in the container wall. This is exceedingly important for containers of the type which hold fluid beverages and the like. A second result of this folding back of the bottom-most portion of the side walls upon themselves is that a double-wall, strong, rigid skirt is provided which will support the container when filled. The skirt is a single continuation of the surface of the container which is never broken. The edge or bottom-most portion of the skirt represents the crease of the fold. It will be recognized that the foregoing is important since this double wall skirt must support the entire receptacle when filled and thus since many containers of plastic are thin walled (being measured in thousandths of an inch, i.e., .005 to 0.20), reinforcing by the supporting skirt portion is truly significant.

Another important feature contemplated by this meth od is that, as the double walls of the skirt are formed by being folded back upon themselves as previously de* scribed, the adjoining surfaces of the double walls are caused to adhere to each other. Assurance is thereby provided that the skirt portions will not be spaced apartand acting independently or separately. The adhering of the folded side walls to each other also allows the bottom} wall to be integrally joined with the upper side walls of: the cup for support thereby, as well as being supported. from below by the depending double thickness skirt,

A further feature of the double thickened skirt at the bottom end of the container is that it serves, togethe? with the normally folded over rolled lip at the open end of the container, as a convenient place for a person to support a very hot beverage since the thermo-conduction characteristic of the doubly thickened portion (i.e. the rim and the depending skirt) is lessthan that of the relatively thinner side portions and affords a person cooler places to carry and support such hot beverages. Another aspect of the sealed skirt portion is that it prevents the lodging of small food particles in the crevises and crannies that would appear in this area if it were not sealed. This is particularly important in re-usable containers that require cleaning.

Time, in my process, is a very important factor in ac-' complishing the moving of the bottom wall and a portion of the side walls from their preformed positions to their final positions. The time interval between the imposition of the pressuer differential to the hot thermoplastic mate rial to accomplish the initial preforming, and the step of moving the bottom wall and a portion of the side walls to their final position, must be exceeding short.-

To insure a good tight seal of the bottom wall portionof the container with the upper side walls of the con-' tainer, after it has been raised from the preformed posi--' tion, I have found that it is expeditious to form an an' nular inwardly directed shoulder in the mold which assures contact of the marginal edge of the bottom portion with the upper side wall portions to allow the material to reunite or flow together. Since the mold cavity surrounding this internal shoulder is cool, it is apparent that the movement of the bottom portion must be quickly accomplished in order to join the materials prior to setting thereof.

As will become apparent by the specific discussion of the methods and machine by which I provide this novel false bottom container, I have invented two major methods by which the bottom portion and bottom side wall parts of the preformed container may be moved front their preformed position to their final position. The first method is to do it mechanically with a heated (or at least relatively warm) movable end portion of the mold cavity, the movement of the end portion of the cavity being accomplished by a cam actuation off a drive shaft which has the advantage of being adjustable to accommodate a large number of different mold sizes and rapid stroke changes. An alternative to cam actuation is pneumatic actuation using the same air supply as disclosed herein for the initial preforming stage and by merely placing another outlet to the air supply at the pneumatic actuator downstream of the outlet which creates the pressure difierential. The time differential necessary between preforming and moving the bottom portion of the mold cavity upwardly is afforded by the short time interval it, takes the pressure front to traverse the distance between. the upstream outlet and downstream outlet at the pneu" matic actuator.

The second major method of forming the false bottom container is basically that of using the: male mold member or mandrel which does the initial mechanical; draw ing as an abutment means in the third operation subsequent to the second operation which may be called the performing stage. In the third operation, the mandrel is re-engaged with the web of material and serves as an abutment means stopping the bottom portions of the container in its finally formed position. The movement of the end portion of the preformed container from the second or preforming stage to the third and final stage being accomplished by reversing the pressure differential of the preformed stage so as to cause the bottom portions of the container to move in the reversed direction from the movement in the preforming stage for abutment against an internal shoulder of the mold and the end surface of the male mandrel.

While the foregoing has been discussed in quite general terms, it is believed that it will serve as an introduction to the understanding of the more detailed discussion that will now follow.

Referring now in greater particularity to the drawings, and first to FIGS. 1 to 3, there is shown a machine for molding containers, such as false bottom cups, from plastic sheet material. While this specification will discuss this invention in terms of cups, the term should not be considered limiting as the invention has application to articles of many natures and uses. The machine includes a frame 32 having thereon a drive motor 34 driving a speed reducer 36. The speed reducer drives a chain 37 which in turn drives a shaft 38. The shaft 33 is provided at its opposite ends with cams 40 cooperable with cam followers or rollers 42 at the lower ends of push rods 44 journaled in a cross member 46 of the frame 32, and further guided by guides or sleeves 43 adjacent the lower ends of the push rod 44. The push rods 44 support at their upper ends a horizontal cross head 53. The push rods are provided with rollers 52 coaxial with the rollers 42 and these rollers 52 are positively forced down by the cam flanges 5d axially directed on arms 56 secured at the ends of the shaft 38 outwardly of the cams an.

The shaft 33 is jounraled in bearings 58 supported from a transverse portion 80 of the frame, the bearings being spaced in from the ends of the shaft. Between these bearings and adjacent thereto the shaft is provided with a pair of cams 62 cooperable with cam followers 64 at the lower ends of push rods 66 journaled in bushings or the like 58 mounted on a fixed central plate portion 69 of the frame. A mold 7 3, having a plurality of cavities therein, and subsequently to be discussed in greater detail, is supported at the tops of the push rods 66 for vertical movement as controlled by the cams 62. The mold or die 78 is provided with lateral base extension 72 cooperable with a fixed member 74 on the frame portion 69 to guide the mold means or die '76 in vertical movement.

The transverse frame member is provided with a depressed central section 75 having a pair of bushings 78 mounted thereon. Posts or connecting rods 8t extend vertically through these bushings and through aligned apertures in the depressed central section 76 of transverse frame member 46. The connecting rods or posts 89 are fixed at their upper ends to cross head and move vertically therewith. The connection is a screw set arrangement, as will be seen particulany in FIG. 2 and this allows for a certain amount of vertical adjustment. Molding head 82 is secured to the bottom of the posts or connecting rods 80 and includes a plurality of downwardly directed mandrels or male die members 84 aligned with corresponding cavities 86 in the mold 70. In the specific illustrative embodiment, there are two rows of four mandrels or eight mandrels in all. This is, of course, semidiagrammatic and not intended to be limiting.

Four posts 88 depend from the depressed central section 76 of transverse frame member 46 adjacent the corners of the molding head 82, but spaced outwardly therefrom, in support of fixed clamping plate 9%. This plate is provided with a plurality of apertures 92 respectively aligned with the mandrels S4 and through which 6 the mandrels extend in a molding operation, as hereinafter will be set forth. The plate further cooperates with portions of the mold to secure a plastic sheet for molding, as will be set forth hereinafter.

A pair of rods 94 is mounted on the cross head 5% relatively adjacent the opposite ends thereof. The rods extend through suitable holes in the transverse frame member 46, and are provided at their lower ends with adjusb. able stops or spring anchors 96 conveniently comprising nuts and washers. A helical spring 98 encircles each rod and is compressed between the transverse frame member 46 and the corresponding stop or spring anchor or seat 95. Accordingly the cross head 50 and the push rods 44 are urged resiliently down, whereby to hold the followers 42 resiliently against cam 40. The transverse frame member 46 also is provided with adjustably fixed stops 10%) adjacent its opposite ends and engageable with the cross head 50 to limit downward movement thereof.

7 The fixed frame parts supporting the fixed plate 69 and mold guide 74, such frame part hereinafter being identified by the numeral 1192, are provided at their upper edges with upstanding supports 104 which support upper belt guides I06 and lower belt guides 103. The guides 106 and 108 are spaced apart only a short distance, and are provided with pairs of confronting grooves 110 and 112 respectively.

h The guides 106 and 108 further are supported at their ends by supports 114 (see FIG. 1) upstanding from the frame. The ends of the guides are provided with oppositely extending and diverging supports comprising upper supports 116 and lower supports 118 and are provided with journals rotatably mounting a pair of spaced upper rollers 12% and a corresponding pair of spaced lower rollers 122. Each roller is provided with four V-grooves, one pair near each end, receiving two pairs of upper V-belts 124 and two pairs of lower V-belts 126.

The lower roller 122 at the entering end of the machine (the right end as viewed in FIGS. 1 and 3} is provided with a sprocket 128 driven by chain 130 from a sprocket 132, the latter being intermittently driven by suitable mechanism incorporated in the speed reducer 36. Intermittent motion mechanisms are Well known in the art, and any suitable type may be used. Further, the entering end rollers 12! and 122 are geared together by suitable meshing gears 134 and 136, whereby the belts 124 and 126 are driven intermittently and in synchronism. A web or film 138 of plastic sheet material stock is fed into the machine through the rollers and 122 at the entering end of the machine, is carried by the belts 124- and past the molding hea d 82 and mold 70 and emerges from the machine through the discharge rollers 120 and 122 as scrap 14%. Plastic sheet material preferably is of the thermoplastic variety, and polystyrene, for example, has been used with success. The sheet material may be fed from a suitable storage roll or directly from an extruder which makes such forms of sheet material.

In order to insure proper plasticity of the sheet stock, there may be provided an electric resistance heater 142. (or other suitable type such as infra-red heaters) suitably supported above the web 138 between the entering end of the machine and the mold and molding head. This heater conveniently may be supported from a fixed portion of the machine such as the belt guide 108.

In addition to the foregoing, there is provided immediately adjacent the entering end of the mold and molding head, an air pipe 144 connected to a suitable source (not shown) and having jets in the side thereof at 146 directing air under pressure to blow finished containers away from the mold and onto a conveyor or other suitable means to carry the products away.

It has been found that the containers produced by the above machines are stronger if the plastic sheet material from which they are made is initially stretched biaxially. Therefore, modification of the machine to accomplish this is shown in FIG. 4. The plastic sheet material is 7 gripped along its opposite edges by diverging pairs of belts (:which accomplish the desired transverse stretching) 147 in FIG. 4.

It will be understood that there are a pair of belts above the plastic sheet material along each edge and also a pair of belts below the plastic sheet material along each edge, and aligned with the upper belts. The beltsare preferably backed up by suitable rollers or guide means to maintain suflicient clamping pressure on the. edges of the material.

Means is provided for restraining or holding back the sheet material, and it is illustrated as being a roller 148. The surface speed of the roller is less than the speed of the belts 1 -2-7, and hence the belts cause the material to be stretched longitudinally as indicated by the arrows 150. According to one form of the invention, the plastic material is fed directly from the extruder and hence is still warm and pliable. However, in some instances, whether from an extruder or from a storage roll, the plastic may have to be heated to a certain extent, and heating means such as electric heaters or infra-red heaters are provided as necessary. One such heater is indicated at 152.

Subsequent treatment of the plastic sheet material, as. to the molding of the articles is similar to that previously alluded to, and hereinafter described in greater detail. Further reference to this point is believed unnecessary, in view of the use of similar reference numerals to those previously used with the addition of the suffix (a). As will be noted adjacent the left-hand portion of FIG. 4,

the material has been stretched biaxially as indicated by the horizontal number of arrows.

Referring now to FIG. 5, the molding head 82 may be designated as a combination clamping, cut-off and mandrel means, and comprises a mounting plate 156 having an annular ring recess 158 in the vicinity of the mandrel 84 illustrated. In recess 158 is a central depending boss 160 which supports the mandrel 84 and is provided with a plurality of apertures 161 which are connected to an air inlet pipe 163. It will be appreciated, that a manifold or the like is provided to provide air under pressure concurrently to all of the inlet pipes 163, there being one such inlet for each mandrel 84. Air is supplied from any suitable compressor or the like 166. (shown schematically in FIG. 14) to flexible hoses 164 (see FIGS. 2 and 14) through the use of a suitable .valving means 165 or any other commercially known satisfactory expedients. The valve means 165 may be actuated by cam 167 mounted on shaft 38. (It will be appreciated that the disposition of cam 167 and valve 165, as shown in FIG. 14, is to be considered semidiagrammatic.)

The mandrels 84 as shown are substantially in the shape of the frustrum of a cone and are provided with substantially flat bottom surfaces 168. The mandrels 84 are preferably heated by suitable means (not shown) for the reasons hereinafter set forth. As set forth in my aforementioned application, the outlets 161 may be in the mandrel 84 per se if desired.

It has been found that one essential feature of a mandrel 34 is that it does not extract any substantial amount of heat from the material being molded. It will be appreciated that if heat is extracted from the previously heated plastic sheet material during the molding operation, the sheet loses its elasticity and resists further forming or deformation. A predetermined degree of cooling of the material upon contact with the mandrel is desirable to prevent unwanted sliding of the material over the entering end of the mandrel; it is imperative that the sheet is not substantially chilled by the mandrel. Another essential is that the sheet material must not slide in an uncontrolled manner over the bottom end of the mandrel. Such sliding results in thinning of the sheet material in the vicinity of the bottom of the mandrel, with a resulting thin bottom for the cup or other container.

The mandrels 84 may be made of wood, plastic or metal. In order to avoid extraction of heat from the sheet plastic material by the mandrel, there may be provided a heater within the mandrel which may be an electric heater having lead wires of suitable types. It should be emphasized that the mandrel does not heat the sheet material which in the case of polystyrene has been found to mold satisfactorily at a temperature of 24G-260 F. Metal mandrels, such as aluminum or steel, have been found to operate substantially satisfactorily if operated at a temperature of F. or 250 F. There is no known explanation at the present time as to why two such widely separated temperatures operate satisfactorily, however, actual tests show that this is a fact. Structure or means by which anti-skid or anti-slipping qualities are imparted to the entering end of the mandrel will not be discussed as they are set forth in more detail in my copending United States application, Serial No. 243,166.

Cavity 86 of the die or mold means 70 is aligned with a corresponding mandrel 84. The upper portion of the cavity is provided with a generally frusto-conical shape generally complementary to the mandrel. Adjacent the bottom of the cavity 86 and complementary to the extended position of the mandrel 84, with a mandrel and cavity 85 in telescoped relation, the side wall of the cavity is formed with an inwardly directed shoulder means 17%) (best shown in FIGS. 11-12) to provide a shelf for reasons that are deemed important and will become apparent.

The shoulder means 17 ti (best shown in FIGS. 11 and 12) is positioned on the side walls of the cavity 86 in a manner to define a relatively large upper portion 171 which has tapering side Walls and a relatively straight or vertical short second side wall portion 173. The upper extremity of the side walls 171 is defined by the lip or shoulder portion 174 and the shoulder means 171 and the second or lower portion 173 is defined by the inwardly curved bottom end portion 172 and the shoulder means 176. More specifically, the shoulder means per se includes a first horizontal portion 176, a relatively short vertical portion 173 and a reversed beveled portion 180. (While these enlargements as shown are considerably greater than actual size, they are fairly accurate in terms of proportion).

As best shown in FIG. 7 of the drawings, the side wall of portion 173 is preferably vertical or parallel with the axis of the mold cavity and the diameter of the side wall 173 preferably is slightly greater than the diameter of vertical portion 178 of the shoulder means 1'70. Further, the second portion 173 of the side wall is preferably slightly less in diameter than the diameter of the side wall of the first portion 171 at the smallest point, i.e. immediately adjacent the shoulder 17 0.

A relatively movable mold element 182 (FIGS. 57) located in the base of the mold cavity performs a triple function in the manufacturing process. First it serves as the bottom wall of the mold 86. Further, it mechanically moves the bottom portion of a preformed container to its spaced final position. Lastly, it serves as a knock-out plug to remove the completely formed container from the mold cavity as will be hereinafter explained. As shown, the knock-out plug or mold element 182 is cylindrical in shape and is normally positioned in a bore 183 of the mold cavity 86 so that top surface 185 is flush with end surface 172 of the cavity. The plug 182 is mounted for relative movement relative to the mold cavity 86 in two distinct ways. First it is mounted on a suitable stern 184 for movement therewith. A lost motion spring 186 may be placed adjacent the lower end of the stem 184 to cooperate with a bushing (not shown) constantly to bias the stem 184 in a downward position as indicated in schematic FIG. 14. The stem 184 and knock-out and forming plug 182 are mounted for relative movement to the fixed portion of the frame 69 by means of a movable plate 188 which is shown most clearly in schematic diagram'FIG. 14. The plate 188 bottoms on fixed frame portion 69 and is movable upwardly therefrom by an actuating post 192 which is mounted in a suitable bushing 198 (shown in FIG. 20). The actuating post 192 has a cam follower 194 mounted at the bottom end thereof which is engaged by a cam 196 which is mounted on shaft 38. As can be seen quite clearly in FIG. 14, rotation of shaft 33 will cause cam 196 to engage roller 194 to in turn lift actuating post 192 to in turn cause upward movement of plate 188 which in turn causes a relative movement of the knockout and forming plug 182 relative to the mold cavity as, the latter being mounted on separate cam actuated posts 66.

The second relative movement of the plug 182 to the cavity 86 is obtained when plate 188 is bottomed on frame 69 and the cavity 86 is moved downwardly to cause ejection of the container as will be explained. The relative sequence of this operation together with other operations of the device will become more apparent during the discussion of the operation of the machine.

The knock-out and forming plug 182 is preferably formed of a porous sintered material 17 which permits equalization of fluid pressure on both sides of the plug 182. The same result may, of course, be accomplished by making the element 182 of solid material but providing it with a central insert of permeable material, i.e. which affords a passageway for equalizing pressure differentials for the purposes as will be later explained.

As clearly shown in FIG. 5 the upper portion 174 of the mold 86 is rounded at the top end thereof and on the outside of the entering end is a short shoulder 198 which adjoins a relatively vertical annular surface 290. This portion of the mold together with clamping and cutoff edge 202 of the recess 158 of the mandrel means 84 serves to clampingly engage the membrane of plastic material after it has meen mechanically pro-drawn by the mandrel portion 84. (This is in accordance with the teachings of my co-pending application 243,166 aforementioned.)

To clamp the web of plastic material 138 for the mechanical drawing thereof by the mandrel 84, an annular ring-like clamping means 204 cooperates with clamping plate 90 to engage the web of material just prior to and during the mechanical drawing operation. The lower clamping means 204 cooperates with clamping plate 0 to engage the web of material just prior to and during the mechanical drawing operation. The lower clamping means 284 is provided with an annular recess 2% which receives a helical spring 2% to resiliently urge surface 21%) of the clamping ring 204 into engagement with the thermoplastic material.

Before discussing the sequential operation of the machine, it will perhaps be helpful to identify certain portions of the container in its preformed state and in its finished state. The completely formed container will be identified with the reference numeral 212 and the preformed or intermediate stage container will be identified by the reference numeral 214 as shown most clearly in FIG. 7 of the drawings. The preformed container 214 has an upper portion 215 and a lower side wall portion 216 which together provide the side walls of the preformed container which is of complementary shape to the mold when the plug 182 is in the position shown in FIG. 7 of the drawings. The bottom surface of the preformed container 218 is immediately adjacent the top surface of the plug 182.

The finally formed false bottom container 212 is depicted in FIG. 10 as it is being removed from the mold and has a double thickness skirt portion 220 and a spaced bottom surface 221 which is spaced from the edge 21? of the skirt or depending portion 229.

Operation The motor 34 is energized causing movement of the thermoplastic web 138 into the machine. Shaft 38 is rotated to cause cams 49, (i2, 196 and 167 to rotate there- With to cause actuation of the parts in a sequential operation as shall now be described. (For purposes of ease of understanding, the semidiagrammatic view of FIG. 14 will be used in this discussion.) The cams 44 cause posts 44 to move the upper mandrel 84 in a downwardly direction and the cams 62 cause plate 72 to move upwardly which in turn causes the mold cavity 86 and plug 182 to move upwardly.

As the shaft 33 rotates, the mandrel means 84 and the mold cavity 86 are brought towards each other in a manher to first cause the under clamping means 204 to en gage the material 138 to clamp it relative to clamping plate to form an intermediate clamping arrangement. Thereafter the mandrel 84 engages the material 13 until the mechanical draw is completed and the ring 158 of the mandrel means and edge 202 thereon engage and clampingly hold the material 138 against portions 174 and 198 as shown in FIG. 6.

At this time earn 167 has rotated into engagement with valve to open passageway 164 to the air pressure supply means 166 to afford a pressure differential to the membrane 138 through inlet 163 and outlets 161 of portion 160 of the mandrel. As shown in FIG. 7, a positive pressure shown by the directional arrows, causes separation of the heated thermoplastic material from the mandrel 84 and engagement of the material 138 with the side Walls of the mold cavity to take a complementary configuration thereto. Immediately after the material 138 assumes the position shown in FIG. 7 and While the pressure differential still is in existence, cam member 196 actuates movable plate 188 causing plug 182 to move relative to cavity 86 from its position shown in FIG. 7 to the position shown in FIG. 8. It is to be emphasized that the timing of this movement of the plug 182 must occur very shortly after the operation shown in FIG. 7 and preferably is less than a tenth of a second thereafter. The relative diameter of the plug 182 and the second portion 173 of the side walls is such that it causes the material on the bottom half of the side wall second portion 173 to fold back and adhere to itself. As the plug 182 moves relative to the portion 173 of the mold, the preformed container walls 216 peel 011 the sides walls rather than losing their identity such as would occur in a pressure or injection molding type of action. It is thought that this occurs because the side walls 173 are relatively cool which causes an almost instantaneous partial setting of the preformed container Wall portion 216, so as to allow the walls to retain an identity until they are in the position shown in FIG. 8 whereupon the inner surfaces more or less flow together.

The top surface of the combination knock-out plug and forming member 182 is brought into substantial alignment with the reversed taper portion of the shoulder means 179 to cause the marginal edges of the material forming the preformed container portion 218 to adhere to the side walls adjacent the tapered portion 180. Thus the bottom portion of Walls 216 and bottom portion 218 of the preformed container 214 are moved to their final position and held there by the adherence to the side walls in a position adjacent the shoulder means 17%, there being a tight seal completely around the margin of the bottom portion 218 in its final form.

To allow quick retraction of the combination knock-out plug and forming member 182 to its original position at the bottom of the mold 186 while allowing the bottom porion of the container and the double thickness of the side wall skirt portion to remain in a position shown in PEG. 8, the knock-out plug is permeable so that it may be retracted without creating a vacuum immediately adjacent the bottom wall 218 of the formed container. As mentioned earlier in the specification, a small insert of a permeable character in the plug 182 is sutlicient to prevent a vacuum from forming adjacent the material and the plug when removing same, and it is not necessary to cause a positive pressure in this area to efficaciously move the knocked-out plug 182 back to its spaced relation or position at the bottom of the mold. As aforementioned, at the same time that the plug 182 is being raised to its second position adjacent the shoulder 17%, the air pressure differential created by the cam 167 remains in effect. The air pressure does two things, namely, provides a resilient bias so as to cause the bottom portion 218 of the container to be formed in a straight manner and secondly helps to chill the warm thermoplastic material so it will retain its formed state.

While the knock-out and forming plug 182 is being retracted, the air pressure is released and the combination cut off, clamping and mandrel member is moved downwardly to its third position to shear the formed container from the remaining scrap material 140 as shown in FIG. 9. The release of the air pressure and the chilling action of the mold cavity on the thermoplastic material causes the container 212 to shrink rather uniformly throughout its extent (except where held at the top of the cavity) so as to move the side walls of the skirt portion 220 inwardly a predetermined dimension and sufiicently to be clear of the shoulder means 170 (as shown in FIG. 9). Thus, after a short time delay, and after the mandrel 84 is moved up to its original position by cams 40, when cams 62 move the plate 72 and cavity 86 downwardly relative to the plug 182 (which bottoms on plate 188 and fixed frame 69), the top surface 194 of the plug 182 engages the double thickness skirt portion 220 to eject the formed container 212 from the mold, whereupon the formed container 212 is moved for packaging by the air jets 146 as mentioned hereinbefore. While the formed container 212 is being ejected from the cavity 86 and blown away by the jets 146, the material 138 is simultaneously moved into position for the new cycle to begin.

The time cycle of the operation above described when applied to cups is approximately two seconds, broken down as follows:

(It should be noted that this is an example only, as the cycle will be varied depending on the configuration and size of the container, this particular cycle pertains to thin wall containers such as seven ounce cups having a final wall thickness of five to ten thousandths of an inch.)

Approximately one-third of the cycle time (two-thirds of a second) is required for the simultaneous happening of the movement of the fresh web stock 138 into position for engagement with the underside of the clamping means 91 and the ejection of the formed container 212 from the mold cavity 86 by the plug 182 when the cavity 86 is moved downwardly relative to the plug. Approximately one-third of the time (two-thirds of a second) is required for the simultaneous movement of the cavity 36 upward and the mandrel means 84 downward to clamp the material 138 and mechanically draw same to the position shown in FIG. 6. The other or remaining one-third of the time cycle accomplishes the three stages shown in FIGS. 7, 8 and 9. However, of this last one third of the cycle (two-thirds of a second), by far the greatest portion of the time is utilized in the cutoff of the rim of the formed container and the retraction of the mandrel 34- toward its starting position to afford clearance for the ejection of the formed container 212. Stated another way, only a very small fraction of this two-thirds of a second is required to preform the container 214 by the opening of valve 165, and the movement of the plug 1&2 from the bottom of the cavity to its position adjacent the shoulder means 170 and its return to the bottom of the cavity 86 and the release of the valve 165 to release the pressure ditferential.

An alternate method of actuating the combination knock-out and forming plug 182 relative to the mold cavity 86 for moving the container bottom portions in the final forming stage, is shown in FIG. 14a wherein like parts have been denominated with primed numerals. Only the operation of the plug 182 has been schematically presented, it being understood that the other operations are accomplished substantially as shown in FIG. 14 and FIGS. 1 thru 4 of the drawings aforementioned. As shown in FIG. 14a the air supply 166' has a similar valve means which allows an air pressure to be presented to the mandrel 84' through outlet 163. On the downstream side of outlet 163 is suitable passageway means including fiexible tubing 222 which is attached to an outlet 223 for actuating an air cylinder 224. No timing device is needed to cause the air cylinder 224 to actuate subsequent to the movement of the air pressure around mandrel 84' to form the material as shown in FIG. 7 since the time differential imposed by the time it takes for the pressure front to reach the second outlet downstream from the first outlet 163' makes certain that the combination knock-out and forming plug 182' moves up to form the bottom portion of the false bottom container subsequent to engagement of the thermoplastic material to the confines of the mold 86. It will also be apparent that the time differential is very short. Another way (not shown) to accomplish the same result is to have two air lines at a Y-connection downstream of the valve means 165, one line going to the outlet 163' and the second line going to the actuator 224. The second line should be slightly longer than the first air line and in actual test it has been found that a differential in length of only two inches gives the desired short interval between the two operations.

Another alternate embodiment of the invention as shown in FIGS. 15 thru 17 is portrayed with similar parts identified by the same reference numbers double primed. In this latter embodiment, the knock-out plug 182" does not physically move the material in the forming operation as discussed heretofore in the other embodiments. Rather, plug 182" has an insert 197 of sintered metal which serves as an outlet for a second source of fluid pressure attached to source 166" which is communicated through a supply pipe 226 which is formed in plug 182". Thus the fluid pressure causes the movement of the bottom 218" of the preformed container while plug 182" remains stationary. A heater 228 is preferably formed directly into the knock-out plug 182 (as discussed with the earlier embodiments but not shown), having suitable leads 230 and 232 extending therefrom. The plug 182" is preferably sealed relative to the mold portion 183" by suitable means 234. Also venting means 236 is provided for egress of trapped air during the preforming stage.

In this embodiment separate valving must be used for pipe 226 since the air pressure utilized in preforming the container through outlets 161" associated with mandrel 84" as shown in FIG. 15 must be released prior to forming a positive pressure through supply pipe 226 in the plug 182". As shown, the supply pipe 226 may help create the pressure differential used in preforming as shown in FIG. 15 by evacuation, or may be used to create the pressure differential alone by creating a vacuum on the underside of the mechanically drawn container, thereby drawing the material into the position shown in FIG. 15. In this latter event the outlets 161" and supply pipe 163 may be eliminated.

As shown in FIG. 16, the bottom 168" of the mandrel 84 also serves the function of providing an abutment means or stop upon which the bottom portion 218" of the preformed container 214" impinges when a positive pressure is introduced through supply pipe 226 to thus allow the bottom 221" of the finally formed container 212" to obtain a regular flat surface. It is necessary in this embodiment to vary the sequential operation by causing the cutoff step to be prior to the movement of the reformed container bottom portions 218, the remainder of the container being held in engagement in fixed position around the periphery at the lip of the container by the combination cutoff and clamping means. Thus, in

this embodiment, the mandrel 84 first mechanically draws the material, then it is molded to the preformed state by the air pressure difierential created either by outlet 226, or 151 or both, then the mandrel 34" is moved downwardly just adjacent the shoulder means 17%" in the mold cavity the bottom surface 168" thereof to serve as a mold member when a reversed pressure differential is placed on the material as shown in FIG. 17. The shoulder means 176" in the mold cavity prevents the material from flowing up the sides intermediate the mandrel 3s" and the mold cavity and thus a false bottom container 212" is formed having the characteristics aforementioned. Then, as before, the mandrel 84" is removed upwardly and the container 212" is allowed to shrink suliiciently so that when the mold is moved downwardly relative to the plug 182" the container is ejected as before.

From the foregoing description it will be apparent that the machine is well adapted to mass manufacturing techniques, and that by the methods employed, a container of superior characteristics with a false or concaved bottom characteristic is produced.

Although specific embodiments have been shown and described, it is with full awareness that many modifications thereof are possible. The invention, is not to be restricted except insofar as is necessitated by the prior art and by the spirit of the appended claims.

I claim:

1. The method of forming a container from relatively thin heated thermoplastic sheet material including the steps of mechanically drawing the material with a mandrel, introducing a fluid pressure diffe ential across the sheet material to expand the mechanically drawn material into engagement with a chilled open bottomed mold cavity to preform a container having cooled side walls, a bottom portion at a substantially greater temperature than the cooled side walls and an open end portion, and then quickly moving the bottom portion of the preformed container which traverses all but a small peripheral area between the cooled side wall portions of the container toward the open end thereof in a manner to cause a portion of the side walls to be folded from a first position to a generally opposed position for adherence to other portions of the side walls to form a false bottom container.

2. The method of forming a container from thin heated thermoplastic material comprising, mechanically drawing the material with a heated mandrel, introducing fluid under pressure to one side of the material to cause separation from the mandrel and engagement with a cooled open bottomed mold cavity to preform a container having cooled side walls, a bottom portion at a substantially greater temperature than the cooled side walls, and an open end portion, ceasing the fluid pressure on said one side of the thermoplastic material, and then quickly introducing fluid pressure on the other side of said thermoplastic material against a predetermined area of said bottom portion spaced radially inwardly from the juncture between said side walls and a bottom portion by an amount not substantially greater than twice the side wall thickness for moving said predetermined area of the bottom portion toward the open end of said preformed container for re-engagement with a portion of the mandrel and for causing the side Walls adjacent said bottom portion to fold back from a first to a generally opposed position for adherence to themselves.

3. The method of forming a container from thin heated thermoplastic material comprising, mechanically drawing the material with a mandrel, introducing a fluid pressure differential across the material to cause separation from the mandrel and engagement with a chilled annular mold cavity having an inwardly directed annular shoulder intermediate the ends thereof to preform a container having cooled side walls, a bottom portion at a substantially greater temperature than the cooled side walls, and an open end portion, and then quickly moving a predetermined area of said bottom portion spaced radially inwardly from the juncture between said side walls and bot tom portion by an amount not substantially greater than twice the side Wall thickness toward the open end of said preformed container to cause a portion of the side walls to fold back and assume an attitude generally opposite its initial position for adherence to themselves, said bottom portion being moved into alignment with said annular shoulder for adherence to the side Walls of the container to thereby form a false bottom container.

4. The method set forth in claim 2 with the additional steps of waiting a predetermined period to afford shrinking of the folded side walls and then removing the formed container from the mold.

5. The method of forming a container from thin thermoplastic material with a male member, a chilled female member and a thernally insulated knock-out mold member comprising moving said male mold member relative to stretched heated plastic material and said female and knock-out mold members and to a predetermined position within said female mold member to partially form a container, injecting fluid under pressure through said male mold member when in its predetermined position to form a container complementary to said chilled female member and said thermally insulated knock-out mold member, and quickly moving said knock-out mold member while said fluid pressure is continuing to be injected and said heated plastic in the vicinity of said knockout mold member is still hot to a position within said female mold member from a spaced position relative to said male and female mold members and folding a wall portion of said formed container from a first to a generally opposed position for adherence to other wall portions to provide a double wall thickness portion on said container.

6. The method set forth in claim 5 including the steps of retracting said male and knock-out mold members, and ejecting said container from the female mold member.

7. The method set forth in claim 5 including the steps of ceasing the injection of fluid under pressure, retracting said male and lmock-out mold members, waiting a predetermined period of time to allow said double Wall thickness portion to shrink, and moving said knock-out mold member from its retracted position to a position spaced therefrom for engagement with the shrunkened double wall thickness portion and removal of the formed container from contact with said female mold member.

References (Iited by the Examiner UNITED STATES PATENTS 167,608 9/ 1875 Gill 6548 843,854 2/1907 Waterman 18-35 2,7 65,493 10/1956 Winstead. 2,891,280 6/1959 Politis 18l9 3,050,773 8/1962 Hagen 264-296 XR OTHER REFERENCES Plastics Engineering Handbook, The Society of the Plastic Industry, Inc., Reinhold Publishing Corporation, New York, 1954, pp. 134, 135, 405, and 406.

ROBERT F. WHITE, Primary Examiner.

MORRIS LIE'BMAN, ALEXANDER H. BRODMER- KEL, Examiners.

M. R. BOWLING, Assistant Examiner. 

1. THE METHOD OF FORMING A CONTAINER FROM RELATIELY THIN HEATED THERMOPLASTIC SHEET MATERIAL INCLUDING THE STEPS OF MECHANICALLY DRAWING THE MATERIAL WITH A MANDREL, INTRODUCING A FLUID PRESSURE DIFFERENTIAL ACROSS THE SHEET MATERIAL TO EXPAND THE MECHANICALLY DRAWN MATERIAL INTO ENGAGEMENT WITH A CHILLED OPEN BOTTOMED MOD CAVITY TO PREFORM A CONTAINER HAVING COOLED SIDE WALLS, A BOTTOM PORTION AT A SUBSTANTIALLY GREATER TEMPERATURE THAN THE COOLED SIDE WALLS AND AN OPEN END PORTION, AND THEN QUICKLY MOVING THE BOTTOM PROTION OF THE PREFORMED CONTAINER WHICH TRAVERSES ALL BUT A SMALL PERIPHERAL AREA BETWEEN THE COOLED SIDE WALL PORTIONS OF THE CONTAINER TOWEARD THE OPEN END THEREOF IN A MANNER TO CAUSE A PORTION OF THE SIDE WALLS TO BE FOLDED FROM A FIRST POSITION TO A GENERALLY OPPOSED POSITION FOR ADHERENCE TO OTHER PORTIONS OF THE SIDE WALLS TO FORM A FALSE BOTTOM CONTAINER. 